Multicontact connector and method of making same



Dec.. 14, 1954 A. G. VOELKNER ETAL 2,697,211

MULTICONTAOT CONNECTOR AND METHOD OF MAKING SAME Filed Dec. 30. 195o 3 Sheets-Sheet 1 Dec. 14, 1954 A. G. voELKNER ErAL. 2,697,211

` MULTICONTACT CONNECTOR AND METHOD OF MAKING SAME Filed Dec. so, 195o 3 shee'ts-sneet z N/ s w if!" //I lll De@ 14, 1954 A. voELKNER ETAL 2,697,211

MULTICONTACT CONNECTOR AND METHOD OF MAK ING SAME Filed Dec. 30, 1950 S5 Sheets-Sheet ,5

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X66 J6@ Z5 ZI 160 United States Patent O MULTICONTACT CONNECTOR AND METHOD OF MAKING SAME Alvin G. Voelkner and Donald J. Cochran, assignors to The Pyle-National Company, a corporation of New Jersey Application December 30, 1950, Serial No. 203,712 Claims. (Cl. 339-102) Chicago, Ill., Chicago, Ill.,

This invention relates tus and electrical connector having such characteristics.

In providing multi-contact electrical connectors, it is frequently desirable to provide a connector of the type having a molded body in which are imbedded a plurality of contact elements. If female contact elements having a split terminal portion and of the type adapted to receivably engage a bayonet-type male contact element are provided, the problem of providing a molded body for the connector structure becomes especiallyI dicult since We have overcome all such receiving portion.

A further object of the present invention is to provide improved contact terminal structures for a molded connector body.

A further object of the present invention is to provide ompound contact terminal for a molded connector ferred embodiment.

On the drawings:

Figure 1 is an end elevational view of the electrical connector constructed in accordance with the principles of the present invention;

Figure 2 is a plan elevational view of a lower mold section with sitioned therein and shown in cross-section, the section being taken on line II-II of Figure l;

Figure is a fragmentary enlarged cross-sectional view taken on line III-III of Figure 2;

Figure 4 is a reduced nector structure with the molding components, the sec tion of the connector member being taken substantially on line V-V of Figure l;

Figure 6 is an exploded elevational view with parts fragmentary cross-sectional View of a compound contact element provided in accordance with the present invention; and

Figure 8 is a fragmentary enlarged cross-sectional view of a single contact member provided in accordance with the principles of the invention.

s shown on the drawings:

The electrical connector of the present invention is indicated generally by the reference numeral 10 and includes a molded body 11 which is integrally molded on the end of connected to the separated parts of acompound contact member indicated generally by the meral 17.

In producing an electrical connector 10, the end of a cable 12 is rst stripped to bare the conductors 14 and 15 and a retainer plate 18 preferably made of an electrically non-conductive material suitably apertured conductors 15 are soldered to separate compound contact member 17.

It will be noted that each of the single contact members 16 is of includes a medial annular As is particularly shown on Figures 6 and 7, the compound contact member 17 includes opposed cylindrical segments 19 and 20 each having a medial rib 19a and 20a, respectively. One end of each of the segments is provided with a recess 19b or 20h arranged to receive the end of one of the conductors 15 and the opposite ends 19e` and 20c form a pair of separated terminal engaging portions.

A block of electrically non-conductive material 21 is terial is placed in encircling relationship relative to the segments 19 and. 20 and the block 21.

After the contact members 16 and 17 have been soltiered to the ends of the conductors 14 and 15 an enclosure assembly is assembled around the split terminal portion of each of the contact members.

In reference to the single contact members 16, a tubular sleeve 23 is placed in surrounding relationship to the contact lingers 16C and 16d and .into abutting engagement with the annular rib 16a.

In reference to the compound contact member 17, a tubular sleeve 24, which could be made of an electrically non-conductive material or which, in any event, has the internal bore thereof rendered electrically non-conductive, for example, through the provisi-on of an electrically non-conductive lining 25, is spaced in surrounding relati'onsl'iip to the terminal engaging portions 19C and 20c and intoengaging abutment with the washer 22. l

A `mold plate .26 is provided in accordance with the present invention and has a plurality of locator p ins 27 extending from one face thereof, the locator pins 27 corresponding in number and size to the male prongs of a lugadapted to cooperate with the contact members 16- and 17 of the electrical connector ill.

In the particular embodiment of the mold plate shown in Figures l and 5, the locator pins 27 are firmly assembled with the mold plate 26 and are spaced .in predetermined alignment relative to protruding portions formed on the mold plate 26 to provide a recess 29 in the molded rubber-like body 11 of the electrical connector 1d (Figure l). l

The mold plate 26 is further provided with an opening 3l) which extends therethrough and which is adapted to pass a bolt 3l having a threaded end portion engageable with the retainer plate 1S, the retainer plate 18 having a suitably threaded aperture formed therein to receive the bolt 31.

lt will be noted upon making reference to Figure 5 that the bolt 31 includes a threaded portion 31a which is of reduced diameter so as to provide a shoulder Sib against v which the retainer plate 13 may be seated, thereby to predetermine the aligned assembly of the retainer plate 18 with respect to the mold plate 26.

Having the structural features of the mold plate 26 in mind, it will be apparent that the contact members 16 and 17 may be connected to the mold plate 26 to form a sub-assembly by locating a washer of insulating material 35 on each of the locator pins 27 and thereafter positioning the tubes 23 on the single contact elements 16 and the tube 24 on the compound contact member 17 to engage and abut the washers sleeves may be drawn up in firm assembly with the mold plate Z6 by threading the bolt 3l in assembly with the retainer plate 13.

Ari upper mold section 33 and a lower mold section 34 are provided, each having a recess 33e and 34a, respectively, together forming a molding cavity of a shape complemeritary to that of the body 11 of the electrical connector it) and into which molding material may be transferred.

A semi-cylindrical cable-receiving recess is also formed in each of the mold sections 33 and 34 and extends outwardly from the molding cavity to one edge of the mold section so that the cable 12. may have its end positioned within the molding cavity.

Along the length ot' of the mold sections 33 and 3d is formed an enlarged recess 33h and 34h which together form a clamp-receiving lteyway. A clamp indicated generally by the reference numeral 36 and made up by a pair of similarly coristructed half-sections shaped to form a front key portion 36a, a central body portion 36h and a rear key portion 36C is securely fastened to the cable 12 upon tightening a plurality of Allen-head screws 37 situated in the front and rear key portions 36a and 36h and adapted to radially collapse the half-sections of the clamp 36 into firm assembly with the cable l2.

The front key portion 36a of the clamp 36 is lirmly locked in place in the keyway recesses 34h and 33h and the rear key portion 36e of the clamp 36 will engagingly abut one side of the mold sections 33 and 34, therefore, the cable i2 will be securely locked to the mold sections 33 and 34 by the clamp 36 during the actual transfer of molding material into the molding cavity so that the cable l2 cannot be displaced under the effects of molding pressure.

The mold plate 26 is also mounted in tirm assembly with the upper mold section 33 and the lower mold section 34 through the provision of a mold plate recess Sli formed in the 'lower Vmold section 34 and a correspond ing mold plate recess formed in the upper mold section 33.

Having positioned the mold plate 2o in the keyway formed by the mold plate recess 38 in the lower mold section 3d and the corresponding recess formed inthe upper mold section 33 and having key positioned the clamp 36 lbetween the upper and lower mold sections 33 and 5d, the connector body l1 is formed by transferring a supply of molding material from a well 39 formed in the upper mold section 33. A suitably powered ram 40 "cooperates with the well 39 and forces the molding material through a plurality of sprues 41 extending between 31 so that the contact members and the semi-cylindrical recess in each the well 39 and the molding cavity. The sprites have outlets 41 wh-ich in this preferred embodiment, are situated near the back end of the molding cavity so that the molding material may flow toward the mold plate 26 and in and around the conductors 14 :and 15, as well as the contacts 16 and 17.

The molding material preferably takes the form of a thermoplastic material, for example, a compounded rubber (either natural or synthetic) or any other electrically non-conductive substance capable of being plasticized and effectively used in a connector structure.

Because of the enclosures formed around the contact fingers 16e and 16d of each of the single contacts 16 and the terminal-engaging portions 19C and Zlio of the compound contact member 17 by the tubular sleeves 23 and 24 and the elements cooperating therewith, none of the material used for forming the body 11 will be forced into the locale of the split terminal-receiving portions of the contacts 16 and 17.

After transfer of the molding material has been coinpleted, the mold may be broken and the clamp 35 and the mold plate 26 removed from the connector itl, whereupon the contact members 16 and 17 will be integrally imbedded in thel molded body 11, together with the washers 31 and the tubular sleeves 23 and 24.

The finished connector 1t) has all of the advantageous features available through the provision of a molded body end split terminal contact members in an integral article of manufacture.

. lthough we have resorted to detail in the description of the preferred structural embodiment of our inventive principles, it should be understood that we wish to embody within the scope of this invention all such modilications as reasonably and properly come within the scope of our 4contribution to the art.

We claim as our invention:

l. connector comprising a contact member having a split terminal-receiving portion, an annular rib extending radially outwardly of said contact member adjacent the split terminal-receiving portion, a rigid insulator sleeve having one end abutting said rib and arranged to surround the split terminal-receiving portion, a washer engaging the other end of said sleeve and operable together with said sleeve to isolate the split terminal-receiving portion, and a molded body integrally imbedding and bonded to the Contact member and the sleeve, said washer being imbedded in said body adjacent one edge thereof and forming an opening free of molding material for said split terminal-receiving portion.

2. A connector comprising an elongated contact member having a medial annular rib and a split terminal portion, a rigid insulator sleeve surrounding the split terminal portion and engaging said rib to provide a molding pressure resistant, insulating enclosure around said split terminal portion and a pressure molded body integrally imbedding and bonded to said contact member and said sleeve, whereby said split terminal portion is isolated.

3. A connector comprising a plurality of contact meinbers each having a split terminal-receiving portion on one end, an annular rib extending radially outwardly on each of said contact members adjacent the split terminalreceiving portion, a rigid insulator sleeve engaging each of said ribs and surrounding each of said split terminalreceiving portions, a washer engaging the other end of each of said sleeves, a retainer apertured to receive the other ends of said contact members and to hold same in aligned assembly, said ribs engaging said retainer and a molded body integrally imbedding and bonded to said retainer, said contact members, said sleeves, and said washers.

4. A connector comprising a cable having a plurality of conductors therein, a retainer plate having a plurality of spaced apart apertures, a contact member carried in each of said apertures aridbeing lirmly connected to the end of a corresponding conductor in said cable, a split terminal portion formed in each contact member, a rigid insulating enclosure surrounding each split terminal portion, and a molded body integrally imbedding and bonded to said retainer plate together with said conductors, said enclosures and said contact members, said body having an opening and said retainer plate having a threaded aperture in registry therewith cooperable with locking means to hold said retainer plate, said contact members and said enclosures in fiirn assembly during molding of said body around the end of said cable.

5. A connector comprising a generally cylindrically conformed contact means having 'a'hollowrigid insulator said contact means and said sleeve, said molded body having a plug-receiving aperture in registry with the end of said sleeve and said socket terminal means.

7. A connector as dened in claim 6 wherein said Contact means comprises a compound contact terminal having a plurality of segments together forming a generally cylindrical contact member.

A connector as deiined in claim 7, and a block of electrically non-conductive material between a portion of each of said segments, whereby one end of said contact member comprises separated terminal-engaging portions.

9. A connector as defined in claim 2 wherein said contact member comprises means providing a plurality of segments together forming .said contact member, a rib portion medially disposed on each of said segments and 5 together with one another forming said medial annular rib.

10. A connector as defined in claim 9, and a block of electricall tion of each y non-conductive material between a porof said segments, whereby one end of said 10 contact member comprises separated terminal engaging portions.

References Cited in the file of this patent Number Number UNITED STATES PATENTS Name Date Desant Dec. 15, 1891 Davis Sept. 6, 1927 McGraw Dec. 22, 1931 Cavanagh et al Sept. 24, 1935 Clark Sept. 17, 1940 Johnson et al Jan. 14, 1941 Drury Apr. 18, 1944 Webber July 10, 1945 Brunner Aug. 14, 1945 Miller et al Mar. 19, 1946 Miller et al May 27, 1947 FOREIGN PATENTS Country Date Great Britain Mar. 15, 1928 

